Resin composition and molded article

ABSTRACT

A resin composition contains: 60 to 95% by mass of polyphenylene ether (A); 35 to 0% by mass of styrene-based resin (B); and 15 to 5% by mass of elastomer component (C). The component (C) is present as dispersion particles in the resin composition. The dispersion particles have a number average particle size of  0.04  to  0.25  μm.

CROSS-REFERENCE TO RELATED APPLICATIONS

The is a Continuation Application of U.S. application Ser. No.15/380,103, field Dec. 15, 2016, which is a Divisional Application ofU.S. application Ser. No. 14/783,122, filed Oct. 8, 2015, which is aNational Stage of the International Application No. PCT/JP2014/060744,filed Apr. 15, 2014, which claims priority to Japanese Application No.2013-086736, filed Apr. 17, 2013. The disclosure of application Ser.Nos. 14/783,122, 15/380,103, and PCT/JP2014/060744 are expresslyincorporated by reference herein in their entireties.

TECHNICAL FIELD

The present invention relates to a resin composition and a moldedarticle.

BACKGROUND ART

Polyphenylene ether resins are excellent in mechanical physicalproperties, electric properties, acid resistance, alkali resistance andheat resistance, and simultaneously have various properties such as lowspecific gravities, low water absorption rates and good dimensionalstability. Therefore, heretofore, the polyphenylene ether resins arebroadly used as materials for household appliances, OA devices, businessmachines, information devices and automobiles and the like.

Particularly in the applications to light-reflecting molded articles andthe like requiring high heat resistance, the demand for resincompositions designed in a higher ratio of the content of apolyphenylene ether resin is anticipated. Such applications also requiregood appearance properties in addition to high heat resistance.Furthermore, the applications require good molding fluidity andpractically sufficient impact resistance.

Heretofore, a method for adding rubber-reinforced polystyrene (highimpact polystyrene) and an elastomer component is used in order to applypractically sufficient impact resistance to the polyphenylene etherresin.

However, the method for adding rubber-reinforced polystyrene hasproblems that it tends to decrease the fluidity of a resin compositionand remarkably impairs the brightness feeling of the appearance of amolded article.

On the other hand, a technique for using high-molecular weight SEBS(hydrogenated styrene-based elastomer) and SEBS having a high boundstyrene content in combination is proposed for the method for adding anelastomer component (for example, see Patent Literature 1).

A technique for using an ethylene-based elastomer component and SEEShaving a high bound styrene content in combination is also disclosed(for example, see Patent Literature 2).

CITATION LIST Patent Literature

-   Patent Literature 1: Japanese Patent Laid-Open No. 2009-197196-   Patent Literature 2: Japanese Patent Laid-Open No. H08 (1996)-151491

SUMMARY OF INVENTION Technical Problem

However, the resin compositions manufactured by the methods described inPatent Literatures 1 and 2 have a problem that the resin compositions donot yet sufficiently have good properties as a practical moldingmaterial.

Then, in the present invention, in consideration of the above-mentionedproblems in the related art, it is an object of the present invention toprovide a resin composition providing a molded article having excellentimpact resistance, and being capable of effectively preventing thedelamination of a molded body, and a molded article thereof.

Solution to Problem

As a result of diligent research to resolve the problems, the presentinventors focused attention on the dispersion state of an elastomercomponent having a remarkable effect on the physical properties of aresin composition, and considered the impact resistance and delaminationprevention of a molded article of the resin composition. As a result,the present inventors discovered that the problems could be resolved byadjusting the dispersion state of the elastomer component in a resincomposition containing 60 to 95% by mass of a polyphenylene ether, 35 to0% by mass of a styrene-based resin, and 15 to 5% by mass of anelastomer component, that is, containing a polyphenylene ether in acomparatively high concentration, thereby completing the presentinvention.

Specifically, the present invention is as follows.

-   [1]

A resin composition comprising:

60 to 95% by mass of polyphenylene ether (A);

35 to 0% by mass of styrene-based resin (B); and

15 to 5% by mass of elastomer component (C),

wherein the component (C) is present as dispersion particles in theresin composition; and

the dispersion particles have a number average particle size of 0.04 to0.25 μm.

-   [2]

The resin composition according to [1] comprising:

60 to 95% by mass of polyphenylene ether (A);

35 to 0% by mass of styrene-based resin (B); and

15 to 5% by mass of elastomer component (C),

wherein the elastomer component (C) is present as dispersion particlesin the resin composition; and

the dispersion particles have a number average particle size of 0.04 to0.25 μm; and the dispersion particles having a particle size of greaterthan 1.0 μm are not present and the number of the dispersion particleshaving a particle size of 0.5 to 1.0 μm is 3 or less in an areacorresponding to an actual measured value of 396 μm² by transmissionelectron microscopy.

The resin composition according to [1] or [2], wherein the elastomercomponent (C) comprises an oil-extended styrene block-hydrogenatedconjugated diene compound block copolymer.

-   [4]

The resin composition according to any one of [1] to [3], wherein theelastomer component (C) comprises an oil-extended styreneblock-hydrogenated conjugated diene compound block copolymer having anoil-extended amount of 20 to 50% by mass.

-   [5]

The resin composition according to [3] or [4], wherein the elastomercomponent (C) comprises the oil-extended styrene block-hydrogenatedconjugated diene compound block copolymer having an oil-extended amountof 20 to 50% by mass and an olefin-based elastomer in a mass ratio of(the oil-extended styrene block-hydrogenated conjugated diene compoundblock copolymer having an oil-extended amount of 20 to 50% by mass: theolefin-based elastomer)=9:1 to 3:7.

-   [6]

The resin composition according to any one of [3] to [5], wherein theresin composition comprises 15 to 100 parts by mass of an oil based on100 parts by mass of the styrene block-hydrogenated conjugated dienecompound block copolymer.

[7]

The resin composition according to any one of [1] to [6], wherein thecomponent (C) comprises a styrene block-hydrogenated conjugated dienecompound block copolymer and/or an oil-extended styreneblock-hydrogenated conjugated diene compound block copolymer and anolefin-based elastomer in a mass ratio of (the styreneblock-hydrogenated conjugated diene compound block copolymer and/or theoil-extended styrene block-hydrogenated conjugated diene compound blockcopolymer/the olefin-based elastomer)=9:1 to 3:7, and the resincomposition comprises 15 to 100 parts by mass of an oil based on 100parts by mass of the styrene block-hydrogenated conjugated dienecompound block copolymer.

-   [8]

A molded article for a light-reflecting part comprising the resincomposition according to any one of [1] to [7].

-   [9]

A molded article for an automotive lamp extension comprising the resincomposition according to any one of [1] to [7].

ADVANTAGEOUS EFFECT OF INVENTION

The present invention can provide a resin composition providing a moldedarticle having excellent impact resistance and an excellent delaminationpreventing effect, and a molded article thereof.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 shows a schematic view of an automotive lamp including a moldedarticle for an automotive lamp extension of the present embodiment;

FIG. 2 shows an electron microscope photograph of an example of a resincomposition in which particles of an elastomer component (a blackportion in FIG. 2) are in a dispersion state satisfying followingconditions (i) to (ii): (i) a number average particle size is 0.04 to0.25 μm; (ii) no particles having a particle size of greater than 1.0 μmin an area of 396 μm² are present; and (iii) the number of particleshaving a particle size of 0.5 to 1.0 μm in an area of 396 μm² is 3 orless. FIG. 3 shows an electron microscope photograph of an example of aresin composition in which particles of an elastomer component (a blackportion in FIG. 3) are in a dispersion state not satisfying at least oneof following conditions (i) to (iii): (i) a number average particle sizeis 0.04 to 0.25 μm; (ii) no particles having a particle size of greaterthan 1.0 μm in an area of 396 μm² are present; and (iii) the number ofparticles having a particle size of 0.5 to 1.0 μm in an area of 396 μm²is 3 or less.

DESCRIPTION OF EMBODIMENT

Hereinafter, an embodiment for implementing the present invention(hereinafter, referred to as “the present embodiment”) will be describedin detail. The present invention will not be limited to the descriptionbelow, but can be modified within the scope of the gist and implemented.

[Resin Composition]

A resin composition of the present embodiment contains: 60 to 95% bymass of polyphenylene ether (A); 35 to 0% by mass of styrene-based resin(B); and 15 to 5% by mass of elastomer component (C).

The elastomer component (C) is present as dispersion particles in theresin composition of the present embodiment; and the dispersionparticles have a number average particle size of 0.04 to 0.25 μm.

It is preferable that the component (C) forms a dispersion phasecontaining the dispersion particles in the resin composition and thedispersion particles having a particle size of greater than 1.0 μm arenot present and the number of the dispersion particles having a particlesize in a range of 0.5 to 1.0 μm is 3 or less in an area correspondingto 396 μm² as measured by transmission electron microscopy.

The dispersion state of elastomer component (C) in the resin compositionof the present embodiment will be described below in detail.

(Polyphenylene Ether (A))

The resin composition of the present embodiment contains polyphenyleneether (A) (herein, may be described as component (A)).

The reduced viscosity of polyphenylene ether (A) is preferably in arange of 0.25 to 0.55 dl/g, more preferably 0.25 to 0.45 dl/g, and stillmore preferably 0.30 to 0.42 dl/g.

The reduced viscosity of polyphenylene ether (A) is preferably 0.25 dl/gor more from the viewpoint of sufficient mechanical physical properties,and is preferably 0.55 dl/g or less from the viewpoints of moldingprocessability and the brightness feeling of a molded article.

The reduced viscosity of polyphenylene ether (A) can be measured in a0.5 g/dl solution under a temperature condition of 30° C. using achloroform solvent.

It is preferable that polyphenylene ether (A) has a repeating unit offollowing general formula (1) and/or (2), and is a homopolymer or acopolymer including a constitutional unit having general formula (1) or(2).

In above general formulae (1) and (2), R1, R2, R3, R4, R5 and R6 areeach independently selected from the groups consisting of an alkyl grouphaving 1 to 4 carbon atoms, an aryl group having 6 to 12 carbon atoms,and a monovalent residue such as a halogen or hydrogen. However, thecase where R5 and R6 are simultaneously hydrogen is excluded.

The alkyl group preferably has 1 to 3 carbon atoms; the aryl grouppreferably has 6 to 8 carbon atoms; and the monovalent residue ispreferably hydrogen.

The number of the repeating units in general formulae (1) and (2) is notparticularly limited because it varies depending on the molecular weightdistribution of polyphenylene ether (A). [0020]

Examples of the homopolymer in the polyphenylene ether (A) include, butare not limited to, poly(2,6-dimethyl-1,4-phenylene)ether,poly(2-methyl-6-ethyl-1,4-phenylene)ether,poly(2,6-diethyl-1,4-phenylene)ether,poly(2-ethyl-6-n-propyl-1,4-phenylene)ether,poly(2,6-di-n-propyl-1,4-phenylene)ether,poly(2-methyl-6-n-butyl-1,4-phenylene)ether,poly(2-ethyl-6-isopropyl-1,4-phenylene)ether,poly(2-methyl-6--hydroxyethyl-1,4-phenylene)ether, andpoly(2-methyl-6-chloroethyl-1,4-phenylene) ether.

Above all, poly(2,6-dimethyl-1,4-phenylene)ether is preferable from theviewpoints of the easiness of procurement of the raw material, and theprocessability.

Examples of the copolymer in polyphenylene ether (A) include, but arenot limited to, copolymers having a polyphenylene ether structure as amain structure such as a copolymer of 2,6-dimethylphenol and2,3,6-trimethylphenol, a copolymer of 2,6-dimethylphenol and o-cresol,and a copolymer of 2,3,6-trimethylphenol and o-cresol.

Above all, the copolymer of 2,6-dimethylphenol and 2,3,6-trimethylphenolis preferable from the viewpoints of the easiness of procurement of theraw material, and the processability; and the copolymer containing 90 to70% by mass of 2,6-dimethylphenol and 10 to 30% by mass of2,3,6-trimethylphenol is more preferable from the viewpoint ofimprovement in physical properties.

The above-mentioned various polyphenylene ethers (A) may be used singlyor combinations of two or more.

Polyphenylene ether (A) may contain a phenylene ether unit other thangeneral formulae (1) and (2) as a partial structure within limits notdeteriorating the heat resistance of polyphenylene ether (A).

Examples of such a phenylene ether unit other than general formulae (1)and (2) include, but are not limited to, a2-(dialkylaminomethyl)-6-methylphenylene ether unit and a2-(N-alkyl-N-phenylaminomethyl)-6-methylphenylene ether unit describedin Japanese Patent Laid-Open No. H01(1989)-297428 and Japanese PatentLaid-Open No. S63(1988)-301222.

In polyphenylene ether (A), diphenoquinone and the like may be bonded ina small amount in the main chain of a polyphenylene ether.

Furthermore, polyphenylene ether (A) may have a constitution in whichpart of or the whole of the polyphenylene ether is substituted by afunctionalized polyphenylene ether by reacting (modifying) part of orthe whole of the polyphenylene ether with a functionalizing agentcontaining an acyl functional group, and one or more selected from thefunctional group consisting of carboxylic acids, acid anhydrides, acidamides, imides, amines, orthoesters, and hydroxy and carboxylic acidammonium salts.

The ratio (Mw/Mn value) of a weight-average molecular weight Mw and anumber-average molecular weight Mn of polyphenylene ether (A) ispreferably 2.0 to 5.5, more preferably 2.5 to 4.5, and still morepreferably 3.0 to 4.5.

The Mw/Mn value of polyphenylene ether (A) is preferably 2.0 or morefrom the viewpoint of the molding processability of the resincomposition of the present embodiment, and is preferably 5.5 or lessfrom the viewpoint of the mechanical physical properties of the resincomposition.

Herein, the weight-average molecular weight Mw and the number-averagemolecular weight Mn are obtained from molecular weights in terms ofpolystyrene according to gel permeation chromatography (GPC)measurement.

The content of polyphenylene ether (A) in the resin composition of thepresent embodiment is in a range of 60 to 95% by mass in 100% by mass ofthe resin composition. The content is preferably in a range of 70 to 90%by mass, and more preferably in a range of 70 to 85% by mass.

In consideration of using the resin composition of the presentembodiment for a molded article for a light-reflecting part, the contentof polyphenylene ether (A) is set to 60% by mass or more from theviewpoint of heat resistance, and is set to 95% by mass or less from theviewpoint of obtaining good molding fluidity.

(Styrene-Based Resin (B))

In the resin composition of the present embodiment, styrene-based resin(B) (herein, may be described as component (B)) can be used as acomponent combined with the polyphenylene ether (A).

The styrene-based resin (B) is not particularly limited, and knownstyrene-based resins can be used.

Examples thereof include a homopolymer of a styrene-based compound, anda copolymer obtained by polymerizing a styrene-based compound and acompound copolymerizable with the styrene-based compound, in thepresence or absence of a rubbery polymer.

Examples of the styrene-based compound include, but are not limited to,styrene, a-methylstyrene, 2,4-dimethylstyrene, monochlorostyrene,p-methylstyrene, p-tert-butylstyrene and ethylstyrene. In particular,styrene is preferable from the viewpoint of the practicality of the rawmaterial.

Examples of the compound copolymerizable with a styrene-based compoundinclude, but are not limited to, methacrylate esters such as methylmethacrylate and ethyl methacrylate; unsaturated nitrile compounds suchas acrylonitrile and methacrylonitrile; and acid anhydrides such asmaleic anhydride.

As styrene-based resin (B), a non-rubber-reinforced styrene-based resinis preferable from the viewpoint of obtaining the appearance of a moldedarticle, and particularly good brightness feeling.

The content of styrene-based resin (B) is in a range of 35 to 0% by massin 100% by mass of the resin composition of the present embodiment. Thecontent is preferably in a range of 30 to 5% by mass, and morepreferably in a range of 20 to 10% by mass.

An effect of improvement in molding fluidity in the resin composition ofthe present embodiment is obtained by adding styrene-based resin (B).The content of styrene-based resin (B) is set to 35% by mass or less in100% by mass of the resin composition of the present embodiment from theviewpoint of securing heat resistance required for molded articles inthe applications to light-reflecting parts such as an automotive lampextension molded article.

(Elastomer Component (C))

The resin composition of the present embodiment contains elastomercomponent (C) (hereinafter, may be described as component (C)).

The resin composition of the present embodiment contains elastomercomponent (C), and thereby improvement in impact resistance is achieved.

A known elastomer component can be used as elastomer component (C), andelastomer component (C) is not particularly limited. Elastomer component(C) preferably contains a block copolymer having a styrene block and ahydrogenated conjugated diene compound block (hereinafter, may also bedescribed as a “styrene block-hydrogenated conjugated diene compoundblock copolymer”) from the viewpoints of the miscibility with component(A) and heat resistance.

The conjugated diene compound block is preferably hydrogenated in ahydrogen addition rate of 50% or more from the viewpoint of heatstability. The hydrogen addition rate is more preferably 80% or more,and still more preferably 95% or more.

Examples of the conjugated diene compound block include, but are notlimited to, polybutadiene, polyisoprene, poly(ethylene-butylene),poly(ethylene-propylene) and vinyl-polyisoprene. The conjugated dienecompound block may be used singly or in combinations of two or more.

The form of the arrangement of repeating units constituting a blockcopolymer may be of a linear type or a radial type.

The block structure composed of a polystyrene block and a rubberintermediate block may be any of two-block type, three-block type andfour-block type. Above all, the block structure is preferably a blockcopolymer of a three-block linear type constituted of apolystyrene-poly(ethylene-butylene)-polystyrene structure from theviewpoint of ability to sufficiently exhibit desired effects in thepresent embodiment.

A butadiene unit may be contained in a range of not exceeding 30% bymass in a conjugated diene compound block from the viewpoint of theimpartation of impact resistance.

The weight-average molecular weight Mw of the elastomer component (C) ispreferably in a range of 50000 to 300000, more preferably 70000 to280000, and still more preferably 100000 to 250000 from the viewpoint ofimprovement in impact resistance. The weight-average molecular weight Mwis preferably 50000 or more from the viewpoint of the impartation ofsufficient impact resistance. The weight-average molecular weight Mw ispreferably 300000 or less from the viewpoints of the fluidity of amolded body, the retention of appearance, and miscibility.

When the elastomer component (C) contains the styrene block-hydrogenatedconjugated diene compound block copolymer, the bound styrene amount ofthe styrene block-hydrogenated conjugated diene compound block copolymeris preferably in a range of 20 to 80% by mass, more preferably 30 to 60%by mass, and still more preferably 30 to 45% by mass. The styrene amountis preferably 20% by mass or more from the viewpoint of miscibility. Thestyrene amount is preferably 90% or less from the viewpoint of theimpartation of impact resistance.

Elastomer component (C) preferably contains an oil-extended elastomercomponent from the viewpoints of improvement in the appearance of themolded article of the present embodiment and improvement in moldingfluidity, and more preferably contains an oil-extended styreneblock-hydrogenated conjugated diene compound block copolymer.

Herein, the oil-extended elastomer component means an elastomercomponent into which a predetermined oil component to be described lateris added.

When elastomer component (C) contains an oil-extended styreneblock-hydrogenated conjugated diene copolymer, the oil-extended amountof the oil-extended styrene block-hydrogenated conjugated dienecopolymer is preferably 20 to 50% by mass, more preferably 20 to 40% bymass, and still more preferably 25 to 35% by mass from the viewpoints ofelastomer dispersibility in the resin composition and impact resistance.

Herein, examples of the oil component include a paraffinic process oil,a naphthenic process oil and an aromatic process oil; a mineral oil suchas a liquid paraffin; and an oil generally used as a softening agent forrubber such as a castor oil. These oil components may be used singly orin combinations of two or more.

When the elastomer component, for example, the styreneblock-hydrogenated conjugated diene compound block copolymer ismanufactured, the copolymer may previously contain the oil component.When the styrene block-hydrogenated conjugated diene compound blockcopolymer is melt-kneaded in an extruder and the like, the oil componentmay be added into the copolymer.

The resin composition of the present embodiment contains, preferably 15to 100 parts by mass, preferably 15 to 70 parts by mass, and preferably20 to 55 parts by mass, of the oil component, based on 100 parts by massof the elastomer component, for example, the styrene block-hydrogenatedconjugated diene compound block copolymer from the viewpoints of thedispersibility of the elastomer component (C) and the prevention of oilbleeding.

When a high-molecular-weight type (Mw: 200000 to 300000) styreneblock-hydrogenated conjugated diene compound block copolymer is singlyused as elastomer component (C), the miscibility of the styreneblock-hydrogenated conjugated diene compound block copolymer in theresin composition is not sufficient, which may cause delamination in themolded article.

For this reason, a middle-molecular-weight type (Mw: 60000 to 150000)styrene block-hydrogenated conjugated diene compound block copolymerhaving a bound styrene amount of 50 to 80% by mass, and an oil-extendedstyrene block-hydrogenated conjugated diene compound block copolymer arepreferably used in combination.

The combination use ratio of the middle-molecular-weight type styreneblock-hydrogenated conjugated diene compound block copolymer having abound styrene amount of 50 to 80% by mass and/or the oil-extendedstyrene block-hydrogenated conjugated diene compound block copolymer andthe high-molecular-weight type styrene block-hydrogenated conjugateddiene compound block copolymer is in a range of a mass ratio of (themiddle-molecular-weight type styrene block-hydrogenated conjugated dienecompound block copolymer having a bound styrene amount of 50 to 80% bymass and/or the oil-extended styrene block-hydrogenated conjugated dienecompound block copolymer: the high-molecular-weight type styreneblock-hydrogenated conjugated diene compound block copolymer)=9:1 to3:7, and more preferably in a range of 7:3 to 5:5.

The other elastomer component of the above-mentioned styreneblock-hydrogenated conjugated diene compound block copolymer can also beused as elastomer (C). Examples of the other elastomer component includean olefin-based elastomer.

Examples of the olefin-based elastomer include, but are not limited to,an ethylene-based copolymer. Specific examples thereof include anethylene-α-olefin copolymer such as an ethylene-octene copolymer, and anethylene-alkyl (meth)acrylate copolymer such as an ethylene-methylacrylate copolymer, an ethylene-ethyl acrylate copolymer, anethylene-methyl methacrylate copolymer, or an ethylene-ethylmethacrylate copolymer.

When the ethylene-based copolymer is used as the olefin-based elastomer,a copolymerization ratio in the ethylene-based copolymer is preferablyin a range of an ethylene component/a component copolymerizable with theethylene component=(60 to 95)/(40 to 5) % by mass, more preferably in arange of (65 to 90)/(35 to 10) % by mass, and still more preferably (70to 85)/(30 to 15) % by mass.

The copolymerization ratio is preferably in a range of the ethylenecomponent/the component copolymerizable with the ethylene component=(60to 95)/(40 to 5) % by mass from the viewpoint of improvement inmiscibility with the styrene block-conjugated diene compound blockcopolymer, heat resistance, and mechanical physical properties and thelike.

The resin composition of the present embodiment contains, as component(C), a styrene block-hydrogenated conjugated diene compound blockcopolymer and/or an oil-extended styrene block-hydrogenated conjugateddiene compound block copolymer and an olefin-based elastomer in a massratio of (the styrene block-hydrogenated conjugated diene compound blockcopolymer and/or the oil-extended styrene block-hydrogenated conjugateddiene compound block copolymer/the olefin-based elastomer)=9:1 to 3:7.The resin composition of the present embodiment contains, preferably 15to 100 parts by mass, more preferably 15 to 70 parts by mass, and stillmore preferably 20 to 55 parts by mass of an oil, based on 100 parts bymass of the styrene block-hydrogenated conjugated diene compound blockcopolymer.

When the olefin-based elastomer as component (C) is singly added intothe resin composition of the present embodiment, the miscibility of theolefin-based elastomer in the resin composition is not sufficient, whichmay cause delamination in the molded article. For this reason, themiddle-molecular-weight type (Mw: 60000 to 150000) styreneblock-hydrogenated conjugated diene compound block copolymer having abound styrene amount of 50 to 80% by mass and the oil-extended styreneblock-hydrogenated conjugated diene compound block copolymer arepreferably used in combination.

The combination use ratio of the styrene block-hydrogenated conjugateddiene compound block copolymer having a bound styrene amount of 50 to80% by mass and/or the oil-extended styrene block-hydrogenatedconjugated diene compound block and the olefin-based elastomer ispreferably in a range of a mass ratio of (the styrene block-hydrogenatedconjugated diene compound block copolymer having a bound styrene amountof 50 to 80% by mass and/or the oil-extended styrene block-hydrogenatedconjugated diene compound block: the olefin-based elastomer)=9:1 to 3:7,and more preferably in a range of 7:3 to 5:5.

In the resin composition of the present embodiment, elastomer component(C) forms the dispersion phase containing the dispersion particles.

For the average particle size of the dispersion particles of elastomercomponent (C), a number average particle size is 0.04 to 0.25 μm,preferably 0.06 to 0.23 μm, and more preferably 0.08 to 0.22 μm. Thenumber average particle size is set to 0.04 μm or more from theviewpoint of the retention of sufficient impact resistance of the resincomposition, and the number average particle size is set to 0.25 μm ormore from the viewpoint of the retention of the appearance of the moldedarticle.

In the resin composition of the present embodiment, it is preferablethat the dispersion particles having a particle size of greater than 1.0μm are not present and the number of the dispersion particles having aparticle size in a range of 0.5 to 1.0 μm is 3 or less in an areacorresponding to 396 μm² as measured enlargedly by transmission electronmicroscopy.

The number average particle size and maximum particle size of thedispersion particles, and the number of the dispersion particles havinga particle size in a range of 0.5 to 1.0 μm, in elastomer component (C)in the resin composition of the present embodiment can be measured byenlarging and observing a core layer (middle layer) part of the pelletor molded article of the resin composition of the present embodimentusing an electron microscope.

The number average particle size of the dispersion particles ofelastomer component (C) can be specifically measured as follows. Asection of the core layer part of the pellet or the molded article ofthe resin composition in a cross-section surface of a surface in a flowdirection of a resin is dyed by ruthenium. The section is then enlargedand shot at a magnification ratio of 50000 with a shooting viewing fieldchanged with the transmission electron microscope. 100 (a total of 500)dispersion particles are selected at random from each of the shot fivephotographs. The number average particle size can be measured by usingthe dispersion particles.

The maximum particle size of the dispersion particles of elastomercomponent (C), and the number of the dispersion particles having aparticle size in a range of 0.5 to 1.0 μm in the predetermined area canbe calculated as described above. That is, a section of the core layerpart of the pellet or molded article of the resin composition in across-section surface of a surface in a flow direction of a resin isdyed by ruthenium. The section is then enlarged and shot at amagnification ratio of 50000 with a shooting viewing field changed withthe transmission electron microscope. By using the shot 25 photographs,the maximum particle size and the number of the dispersion particles canbe calculated from an area corresponding to 396 μm² as measured.

When the above-mentioned dispersion form can be achieved, a specificmaterial for elastomer component (C) can be appropriately selected. Forexample, the styrene block-hydrogenated conjugated diene compound blockcopolymer may be used singly, or the styrene block-hydrogenatedconjugated diene compound block copolymer and other known elastomercomponents may be appropriately used in combinations of two or more.

In the resin composition of the present embodiment, elastomer component(C) which is suitable in order to achieve the dispersion form of desiredelastomer component (C) is an elastomer component containing theoil-extended styrene block-hydrogenated conjugated diene compound blockcopolymer. Furthermore, elastomer component (C) is an elastomercomponent in which the oil-extended styrene block-hydrogenatedconjugated diene compound block copolymer having an oil-extended amountof 20 to 50% by mass and the olefin-based elastomer are used incombination in a mass ratio of (the oil-extended styreneblock-hydrogenated conjugated diene compound block copolymer having anoil-extended amount of 20 to 50% by mass: the olefin-basedelastomer)=9:1 to 3:7.

The content of elastomer component (C) is in a range of 15 to 5% by massin 100% by mass of the resin composition of the present embodiment. Thecontent is preferably in a range of 12 to 5% by mass, and morepreferably 12 to 7% by mass.

The content of elastomer component (C) is set to 5% by mass or more fromthe viewpoint of obtaining impact resistance required as alight-reflecting part such as an automotive lamp extension moldedarticle. The content is set to 15% by mass or less from the viewpointsof heat resistance and the retention of rigidity.

(Other Materials)

To the extent that heat resistance, mechanical physical properties, andthe surface appearance and brightness feeling of the molded article, andthe like are not remarkably deteriorated, the resin composition of thepresent embodiment preferably contains each of various additive agentssuch as a heat stabilizer, an antioxidant, an ultraviolet absorber, anantistatic agent, a lubricant, and a mold release agent at a rate of0.001 to 3 parts by mass based on 100 parts by mass of the total amountof components (A), (B), and (C). The amount of each of the variousadditive agents is more preferably 0.01 to 0.5 parts by mass, and stillmore preferably in a range of 0.2 to 0.5 parts by mass.

The amount of each of these additive agents is preferably set to 0.001parts by mass or more from the viewpoint of the exhibition of asufficient addition effect. The amount is preferably set to 3 parts bymass or less from the viewpoints of the sufficient appearance of themolded article and the retention of physical properties.

The resin composition of the present embodiment preferably contains noinorganic filler as a reinforcing agent as much as possible from theviewpoint of retaining the practically sufficient brightness feeling ofthe molded article obtained by molding the resin composition of thepresent embodiment.

The content of the inorganic filler is preferably 0 to 1 part by mass,and more preferably 0 to 0.5 part by mass based on 100 parts by mass ofthe total amount of components (A), (B), and (C).

The inorganic filler as a reinforcing agent is one commonly used forreinforcing a thermoplastic resin, and examples thereof include glassfiber, carbon fiber, glass flake, talc, and mica.

The resin composition of the present embodiment preferably has aspecific gravity in a range of 1.00 to 1.12 from the viewpoints of aneffect of reducing an environment load by light-weighting, and retainingpractically sufficient heat resistance, mechanical strength, andappearance properties of the molded article, and the like. The resincomposition has a specific gravity, more preferably in a range of 1.04to 1.10, and still more preferably in a range of 1.05 to 1.08.

[Manufacturing Method Of Resin Composition]

The resin composition of the present embodiment can be manufactured bymelt-kneading component (A), component (B), component (C), and the othermaterials if needed.

A condition in which component (C) is adjusted to the above-mentioneddispersion form in the resin composition may be selected as amelt-kneading condition for manufacturing the resin composition of thepresent embodiment.

When the pellet of the oil-extended styrene block-hydrogenatedconjugated diene compound block copolymer is used as component (C), andmelt-kneaded in the extruder to produce a resin composition in a largeamount, the pellet may have high rubber elasticity, being hardly mixedwith the other raw material components, and being classified, thus it ispreferably separated from the other raw materials, and separately singlyfed.

In a manufacturing process of the resin composition of the presentembodiment, a twin screw extruder having a screw diameter of 25 to 90 mmis preferably used from the viewpoint of manufacturing efficiency.

Examples of a suitable method include a method in which when a TEM58SStwin screw extruder (manufactured by Toshiba Machine Co., Ltd., numberof barrels: 13, screw diameter: 58 mm, L/D=53); screw pattern having 2kneading discs L, 14 kneading discs R and 2 kneading discs N) is used,the components are melt-kneaded under conditions of a cylindertemperature of 270 to 330° C., a screw rotation speed of 150 to 800 rpm,an extrusion rate of 100 to 600 kg/h, and a vent vacuum degree of 11.0to 1.0 kPa.

Herein, “L” is a “screw barrel length” of the extruder, and “D” is a“screw barrel diameter”.

When the high-molecular-weight type (Mw: 200000 to 300000) styreneblock-hydrogenated conjugated diene compound block copolymer and themiddle-molecular-weight type (Mw: 60000 to 150000) styreneblock-hydrogenated conjugated diene compound block copolymer having abound styrene amount of 50 to 80% by mass and/or the oil-extendedstyrene block-hydrogenated conjugated diene compound block copolymer areused in combination as component (C), or when the olefin-based elastomerand the middle-molecular-weight type styrene block-hydrogenatedconjugated diene compound block copolymer having a bound styrene amountof 50 to 80% by mass are used in combination, the dispersibility of thehigh-molecular-weight type styrene block-hydrogenated conjugated dienecompound block copolymer component and the olefin-based elastomercomponent in the resin composition may be not sufficiently obtainedunder extrusion conditions to be usually performed; and defects such asfogging and flow mark may occur on the appearance of the molded article.Therefore, the components are preferably melt-kneaded with an extrusionrate set to be lower than normal and the screw rotation speed of theextruder set to be higher than normal.

When the TEM58SS twin screw extruder is used, the extrusion rate ispreferably set to 100 to 300 kg/h, and the screw rotation speed ispreferably set to 500 to 800 rpm. More preferably, the extrusion rate is150 to 250 kg/h, and the screw rotation speed is 550 to 700 rpm. It ispreferable that the extrusion rate is set to 100 kg/h or more and thescrew rotation speed is set to 800 rpm or less from the viewpoint ofsuppressing deterioration in physical properties due to the heatdeterioration of a resin component. It is preferable that the extrusionrate is set to 300 kg/h or less and the screw rotation speed is set to500 rpm or more from the viewpoint of improvement in the appearanceproperties of the molded article.

It is necessary to note that when the resin composition of the presentembodiment is manufactured using a larger twin screw extruder (screwdiameter: 40 to 90 mm), gel and carbide generated from polyphenyleneether (A) during extrusion may be incorporated into an extruded resinpellet to thereby cause the appearance properties and brightness feelingof the surface of the molded article to be deteriorated.

In view of the point, it is preferable that polyphenylene ether (A) ischarged from a raw material-charging inlet at the most upstream (topfeed) and an oxygen concentration in the inside of a shooter on thecharging inlet at the most upstream is set to 15 volume % or less. Theoxygen concentration is more preferably set to 8 volume % or less, andstill more preferably 1 volume % or less.

The oxygen concentration can be controlled by adjusting a nitrogen feedamount and adjusting the opening degree of a gas drain port in additionto sufficiently replacing the inside of a raw material storage hopperwith nitrogen and sealing the way of a feed line from the raw materialstorage hopper to the raw material-charging inlet of the twin screwextruder so as not to allow air to come in and out.

[Molded Article]

A molded article made of the resin composition of the present embodimentcan be obtained by molding the above-mentioned resin composition.

Suitable examples of a method for molding the resin composition include,but are not particularly limited to, methods such as injection molding,extrusion, vacuum forming, and air-pressure forming. The injectionmolding is particularly preferable from the viewpoints of the appearanceproperties and brightness feeling of the molded article.

The molded article of the present embodiment is specified to haveexcellent mechanical physical properties such as heat resistance, impactresistance, and a peeling preventing effect, and to have predetermineddispersion properties in elastomer component (C), and thereby remarkablyexcellent appearance properties can be applied to the surface of themolded article. Therefore, the molded article can be suitably used formolded articles for light-reflecting parts such as a projector andvarious light devices, lamp reflector parts for automobiles, and variousmolded articles for automotive lamp extensions, and the like. Above all,the molded articles for automotive lamp extensions are preferable.

FIG. 1 shows a schematic construction view of an automotive headlampincluding an automotive lamp extension as a molded article of thepresent embodiment.

As shown in FIG. 1, an automotive headlamp includes housing 1 locatedinside an exterior of an automobile, and front lens 2 located on theexterior surface side of the automobile. Light source 3 near whichreflector 5 is disposed, and extension 4 are disposed in a regionsurrounded by housing 1 and front lens 2. An arrow shown by a dashedline in FIG. 1 represents a positional relationship when constitutionmembers of the automotive headlamp are combined.

Light emitted from light source 3 and reflected by reflector 5 isfurther reflected by extension 4, and emitted to the outside of theautomobile from front lens 2.

EXAMPLES

Hereinafter, the present invention is described with reference tospecific Examples and Comparative Examples, but the present inventionshould not be limited thereto.

Measuring methods of physical properties and raw materials used inExamples and Comparative Examples are shown below.

[Measuring Methods of Physical Properties] (1. Deflection TemperatureUnder Load (DTUL))

Each of the resin composition pellets manufactured in Examples andComparative Examples was dried in a hot air dryer at 120° C. for 3hours.

The resin composition after drying was molded by an injection moldingmachine (IS-80EPN, manufactured by Toshiba Machine Co., Ltd.) equippedwith an ISO physical-properties test piece mold, set at a cylindertemperature of 320° C., a mold temperature of 120° C., an injectionpressure of 50 MPa (gage pressure), an injection speed of 200 mm/sec,and an injection time/a cool time=20 sec/20sec, to obtain an ISO3167dumbbell-shaped molded piece as a multipurpose test piece (A type). Theobtained dumbbell-shaped molded piece as the multipurpose test piece (Atype) was cut to produce a test piece of 80 mm×10 mm×4 mm. A deflectiontemperature under load (DTUL) was measured at 1.82 MPa according to aflat-wise method with reference to ISO75 using the test piece.

For evaluation criteria, it was determined that as DTUL is a highervalue, heat resistance is more excellent.

(2. Fluidity (MFR))

Each of the resin composition pellets manufactured in Examples andComparative Examples was dried in a hot air dryer at 120° C. for 3hours. After drying, a MFR (Melt Flow Rate) was measured using a meltindexer (P-111, manufactured by Toyo Seiki Seisaku-Sho, Ltd.) at acylinder setting temperature of 280° C. and at a load of 10 kg.

For evaluation criteria, it was determined that as the MFR is higher,fluidity is more excellent. [0058]

(3. Charpy Impact Strength (Impact Resistance))

Each of the five test pieces of 80 mm×10 mm x 4 mm obtained in the item1 was notched, and a Charpy impact strength was measured with referenceto ISO179.

For evaluation criteria, it was determined that as the measured value ishigher, impact resistance is more excellent.

(4. Molding Appearance (Fogging Feeling))

A dead side grip portion of the ISO3167 dumbbell-shaped molded piece asthe multipurpose test piece (A type) manufactured in the item 1 wasvisually observed to evaluate the presence or absence of the foggingfeeling of the surface of the molded piece in two stages of “good” (nofogging feeling) and “poor” (fogging feeling).

When the surface of the molded piece having fogging feeling was enlargedand observed with a microscope (×60), a number of fine surfaceunevennesses considered to be based on the dispersion particles of theelastomer component (C) were observed. However, an extremely smallnumber of unevennesses were confirmed on the molded piece having goodappearance having no fogging feeling, or the unevennesses were notconfirmed at all.

(5. Molding Appearance (Presence or Absence of Flow Mark))

A gate side grip portion of the ISO3167 dumbbell-shaped molded piece asthe multipurpose test piece (A type) manufactured in the item 1 wasmainly visually observed to determine the presence or absence of theoccurrence of flow mark.

It was determined that the resin composition of the molded piece inwhich the occurrence of the flow mark is confirmed has a poor appearanceproperty.

(6. Bending Of Molded Piece (Brittleness, Peeling))

The ISO3167 dumbbell-shaped molded piece as the multipurpose test piece(A type) manufactured in above 1. was subjected to a bending test, andthe presence or absence of brittleness and delamination in fracture wasvisually evaluated.

A case where the molded piece was not folded up during the bending testand brittle fracture occurred was determined to be a brittle state.

A case where brittleness and delamination did not occur was defined as“good”, and a case where brittleness and delamination occurred wasdefined as “poor”.

(7. Number Average Particle Size of Dispersion Particles of ElastomerComponent (C) in Resin Composition)

The core layer part of the central part of the ISO3167 dumbbell-shapedmolded piece as the multipurpose test piece (A type) manufactured inabove 1., i.e., a section of a cross-section surface in a flow directionwas dyed by ruthenium. The section was then enlarged and shot at amagnification ratio of 50000 with the transmission electron microscope.

There was calculated the number average particle size of the 100 (atotal of 500) dispersion particles of elastomer component (C) extractedat random from each of five photographs shot with a shooting viewingfield changed.

As reference, FIG. 2 shows an electron microscope photograph(magnification ratio: 10000) of an example of a resin composition inwhich the particles of elastomer component (C) (a black portion in FIG.2) are in a dispersion state satisfying following conditions (i) to(iii)

(i) a number average particle size is 0.04 to 0.25 μm;

(ii) no particles having a particle size of greater than 1.0 μm in anarea of 396 μm² are present; and

(iii) the number of particles having a particle size of 0.5 to 1.0 μm inan area of 396 μm² is 3 or less.

FIG. 3 shows an electron microscope photograph (magnification ratio:10000) of an example of a resin composition in which the particles ofelastomer component (C) (a black portion in FIG. 3) are in a dispersionstate not satisfying at least one of following conditions (i) to (iii):

(i) a number average particle size is 0.04 to 0.25 μm.

(ii) no particles having a particle size of greater than 1.0 μm in anarea of 396 μm² are present; and

(iii) the number of particles having a particle size of 0.5 to 1.0 μm inan area of 396 μm² is 3 or less.

(8. Maximum Particle Size of Dispersion Particles of Elastomer Component(C) in Resin Composition, and the Number of Dispersion Particles HavingParticle Size in a range of 0.5 to 1.0 μm)

The core layer part of the central part of the ISO3167 dumbbell-shapedmolded piece as the multipurpose test piece (A type) manufactured inabove 1., i.e., a section of a cross-section surface in a flow directionwas dyed by ruthenium. The section was then enlarged and shot at amagnification ratio of 50000 with the transmission electron microscope.

A portion corresponding to an area of 396 μm² as measured was extractedfrom 25 photographs shot with a shooting viewing field changed. Themaximum particle size of the dispersion particles of elastomer component(C) and the number of the dispersion particles having a particle size ina range of 0.5 to 1.0 μm were calculated from the photographs.

[Raw Materials] <Polyphenylene Ether (A)>

-   (PPE1): Poly(2,6-dimethyl-1,4-phenylene)ether having a reduced    viscosity (measured at 30° C. using a chloroform solvent) of 0.32    dl/g was used.-   (PPE2): Poly(2,6-dimethyl-1,4-phenylene)ether having a reduced    viscosity (measured at 30° C. using a chloroform solvent) of 0.42    dl/g was used.

<Styrene-Based Resin (B)>

-   (GPPS): Polystyrene 685 (trade name) (registered trademark)    manufactured by Asahi Kasei Chemicals, Corp. was used.

<Elastomer Component (C)>

-   (Elastomer 1): A three-block type hydrogenated block copolymer    having a weight-average molecular weight of 100900 and a bound    styrene amount of 60% by mass, and containing a polystyrene block    and a hydrogenated butadiene block having a hydrogen addition rate    of 98%.-   (Elastomer 2): A three-block type hydrogenated block copolymer    having a weight-average molecular weight of 264000 and a bound    styrene amount of 33% by mass, and containing a polystyrene block    and a hydrogenated butadiene block having a hydrogen addition rate    of 98%-   (Elastomer 3): A hydrogenated block copolymer oil-extended in a    ratio of the elastomer 2/ a liquid paraffin-based oil=65/35% by    mass.-   (Elastomer 4): ELVALOY AC1125 (trade name) (registered trademark),    an olefin-based elastomer (ethylene-methyl acrylate copolymer)    manufactured by DuPont-Mitsui Polychemicals Co., Ltd. and having a    methyl acrylate content of 25% by mass.-   (Elastomer 5): A hydrogenated block copolymer oil-extended in a    ratio of the elastomer 2/a liquid paraffin-based oil=54/46% by mass.-   (Elastomer 6): A hydrogenated block copolymer having a    weight-average molecular weight of 105200 and a bound styrene amount    of 29% by mass, containing a polystyrene block and a hydrogenated    butadiene block having a hydrogen addition rate of 98%, and    oil-extended in a ratio of a three-block type hydrogenated block    copolymer/a liquid paraffin-based oil=80/20% by mass.

Example 1

72% by mass of (PPE2), 20% by mass of (GPPS), 4% by mass of an(elastomer 1), and 4% by mass of an (elastomer 3) were supplied from themost upstream (top feed) of a TEM58SS twin screw extruder (manufacturedby Toshiba Machine Co., Ltd., having a number of barrels of 13, a screwdiameter of 58 mm, L (screw barrel length)/D (screw barrel diameter)=53,and screw pattern having 2 kneading discs L, 14 kneading discs R and 2kneading discs N), and melt-kneaded at a cylinder temperature of 300°C., a screw rotation speed of 400 rpm, an extrusion rate of 400 kg/hr,and a vent vacuum degree of 7.998 kPa (60 Torr) to obtain a resincomposition.

The measurement results of physical properties of the obtained resincomposition are shown in following Table 1.

Example 2

72% by mass of (PPE2), 20% by mass of (GPPS), 2% by mass of an(elastomer 1), and 6% by mass of an (elastomer 3) were used. A resincomposition was obtained in the same manner as in Example 1 except forthe condition. The measurement results of physical properties of theobtained resin composition are shown in following Table 1.

Example 3

72% by mass of (PPE2), 20% by mass of (GPPS), and 8% by mass of an(elastomer 3) were used. A resin composition was obtained in the samemanner as in Example 1 except for the condition. The measurement resultsof physical properties of the obtained resin composition are shown infollowing Table 1.

Example 4

72% by mass of (PPE2), 20% by mass of (GPPS), and 8% by mass of an(elastomer 5) were used. A resin composition was obtained in the samemanner as in Example 1 except for the condition. The measurement resultsof physical properties of the obtained resin composition are shown infollowing Table 1.

Example 5

72% by mass of (PPE2), 20% by mass of (GPPS), and 8% by mass of an(elastomer 6) were used. A resin composition was obtained in the samemanner as in Example 1 except for the condition. The measurement resultsof physical properties of the obtained resin composition are shown infollowing Table 1.

Comparative Example 1

72% by mass of (PPE2), and 28% by mass of (GPPS) were used. A resincomposition was obtained in the same manner as in Example 1 except forthe condition. The measurement results of physical properties of theobtained resin composition are shown in following Table 1.

Example 6

72% by mass of (PPE2), 20% by mass of (GPPS), 5% by mass of an(elastomer 1), and 3% by mass of an (elastomer 2) were used. A resincomposition was obtained in the same manner as in Example 1 except forthe condition. The measurement results of physical properties of theobtained resin composition are shown in following Table 1.

Example 7

72% by mass of (PPE2), 20% by mass of (GPPS), 7% by mass of an(elastomer 1), and 1% by mass of an (elastomer 2) were used. A resincomposition was obtained in the same manner as in Example 1 except forthe condition. The measurement results of physical properties of theobtained resin composition are shown in following Table 1.

Comparative Example 2

72% by mass of (PPE2), 20% by mass of (GPPS), and 8% by mass of an(elastomer 1) were used. A resin composition was obtained in the samemanner as in Example 1 except for the condition. The measurement resultsof physical properties of the obtained resin composition are shown infollowing Table 1.

TABLE 1 Comparative Example 1 Example 1 Example 2 Example 3 Example 4(Adding) % by mass PPE2 (component A) η = 0.42 dl/g 72 72 72 72 72 GPPS(component B) 28 20 20 20 20 Elastomer 1 (component C) 4 2 Elastomer 2(component C) Elastomer 3 (component C) 4 6 8 Elastomer 5 (component C)8 Elastomer 6 (component) Total 100 100 100 100 100 Number averageparticle size of μm — 0.06 0.09 0.12 0.10 elastomer in resin compositionMaximum particle size of elastomer in μm — 0.08 0.14 0.23 0.12 resincomposition Number of elastomers (particle size: 0.5 piece — 0 0 0 0 to1.0 μm) in resin composition (Physical properties) DTUL (1.82 MPa) ° C.142 146 147 148 144 MFR (280° C./10 kg) g/10 min 22 23 25 25 33 Charpyimpact strength kJ/m2 0.6 3.6 4.4 6.1 4.8 Molding appearance (fogging)good good good good good Presence or absence of flow mark of moldedabsence absence absence absence absence piece Peeling (ISO dumbbellbending) poor (brittleness) good good good good Comparative Example 5Example 6 Example 7 Example 2 (Adding) % by mass PPE2 (component A) η =0.42 dl/g 72 72 72 72 GPPS (component B) 20 20 20 20 Elastomer 1(component C) 5 7 8 Elastomer 2 (component C) 3 1 Elastomer 3 (componentC) Elastomer 5 (component C) Elastomer 6 (component) 8 Total 100 100 100100 Number average particle size of μm 0.13 0.12 0.05 0.02 elastomer inresin composition Maximum particle size of elastomer in μm 0.25 1.8 1.10.05 resin composition Number of elastomers (particle size: 0.5 piece 08 5 0 to 1.0 μm) in resin composition (Physical properties) DTUL (1.82MPa) ° C. 148 149 148 143 MFR (280° C./10 kg) g/10 min 28 12 18 22Charpy impact strength kJ/m2 7.1 7.5 2.8 1.6 Molding appearance(fogging) good poor poor good Presence or absence of flow mark of moldedabsence presence presence absence piece Peeling (ISO dumbbell bending)good good good poor (brittleness)

As shown in Table 1, the dispersion form of component (C) was in therange regulated in present invention in Examples 1 to 7. Therefore,Examples 1 to 7 provided resin compositions having high impactresistance and a high peeling preventing effect.

In particular, Examples 1 to 5 provided the resin compositions havingwell-balanced physical properties such as heat resistance, moldingfluidity and impact resistance, and exhibiting good molding appearancehaving no flow mark and no fogging feeling occurring on the surface ofthe molded article. The resin compositions could be suitably used as themolded article for the applications to light-reflecting parts.

Meanwhile, the resin compositions of Comparative Examples 1 and 2 didnot contain component (C), or the number average particle size of thedispersion particles was small and beyond the scope recited in thepresent invention even when the resin compositions contained component(C). Therefore, the resin compositions were brittle materials and didnot have sufficient impact resistance.

Example 8

72% by mass of (PPE2), 20% by mass of (GPPS), 4% by mass of an(elastomer 1), and 4% by mass of an (elastomer 4) were used. A resincomposition was obtained in the same manner as in Example 1 except forthe condition. The measurement results of physical properties of theobtained resin composition are shown in the following Table 2.

Example 9

72% by mass of (PPE2), 20% by mass of (GPPS), 6% by mass of an(elastomer 3), and 2% by mass of an (elastomer 4) were used. A resincomposition was obtained in the same manner as in Example 1 except forthe condition. The measurement results of physical properties of theobtained resin composition are shown in following Table 2.

Example 10

72% by mass of (PPE2), 20% by mass of (GPPS), 4% by mass of an(elastomer 3), and 4% by mass of an (elastomer 4) were used. A resincomposition was obtained in the same manner as in Example 1 except forthe condition. The measurement results of physical properties of theobtained resin composition are shown in following Table 2.

Example 11

60% by mass of (PPE2), 25% by mass of (GPPS), 5% by mass of an(elastomer 1), and 10% by mass of an (elastomer 3) were used. A resincomposition was obtained in the same manner as in Example 1 except forthe condition. The measurement results of physical properties of theobtained resin composition are shown in following Table 2.

Example 12

90% by mass of (PPE2), 5% by mass of (GPPS), 3% by mass of an (elastomer3), and 2% by mass of an (elastomer 4) were used. A resin compositionwas obtained in the same manner as in Example 1 except for thecondition. The measurement results of physical properties of theobtained resin composition are shown in following Table 2.

Example 13

90% by mass of (PPE2), 7% by mass of an (elastomer 3), and 3% by mass ofan (elastomer 4) were used. A resin composition was obtained in the samemanner as in Example 1 except for the condition. The measurement resultsof physical properties of the obtained resin composition are shown infollowing Table 2.

Comparative Example 3

72% by mass of (PPE2), 20% by mass of (GPPS), 6% by mass of an(elastomer 1), and 2% by mass of an (elastomer 4) were used. A resincomposition was obtained in the same manner as in Example 1 except forthe condition. The measurement results of physical properties of theobtained resin composition are shown in following Table 2.

Comparative Example 4

72% by mass of (PPE2), 20% by mass of (GPPS), 2% by mass of an(elastomer 3), and 6% by mass of an (elastomer 4) were used. A resincomposition was obtained in the same manner as in Example 1 except forthe condition. The measurement results of physical properties of theobtained resin composition are shown in following Table 2. [0084)

Comparative Example 5

72% by mass of (PPE2), 23% by mass of (GPPS), and 5% by mass of an(elastomer 2) were used. A resin composition was obtained in the samemanner as in Example 1 except for the condition. The measurement resultsof physical properties of the obtained resin composition are shown infollowing Table 2.

TABLE 2 Comparative Example Comparative Example 3 Example 8 Example 9 10Example 4 (Adding) % by mass PPE2 (component A) η = 0.42 dl/g 72 72 7272 72 GPPS (component B) 20 20 20 20 20 Elastomer 1 (component C) 6 4Elastomer 2 (component C) Elastomer 3 (component C) 6 4 2 Elastomer 4(component C) 2 4 2 4 6 Total 100 100 100 100 100 Number averageparticle size of μm 0.03 0.16 0.12 0.16 0.27 elastomer in resincomposition Maximum particle size of elastomer in μm 0.24 1.5 0.26 0.570.77 resin composition Number of elastomers (particle size: 0.5 piece 04 0 1 5 to 1.0 μm) in resin composition (Physical properties) DTUL (1.82MPa) ° C. 149 153 154 158 160 MFR (280° C./10 kg) g/10 min 19 15 20 1713 Charpy impact strength kJ/m2 1.9 2.8 8.3 8.8 3.8 Molding appearance(fogging) good good good good poor Presence or absence of flow mark ofmolded piece absence presence absence absence presence Peeling (ISOdumbbell bending) poor good good good poor (brittleness) (peeling)Comparative Example Example Example Example 5 11 12 13 (Adding) % bymass PPE2 (component A) η = 0.42 dl/g 72 60 90 90 GPPS (component B) 2325 5 Elastomer 1 (component C) 5 Elastomer 2 (component C) 5 Elastomer 3(component C) 10 3 7 Elastomer 4 (component C) 2 3 Total 100 100 100 100Number average particle size of μm 0.38 0.14 0.22 0.11 elastomer inresin composition Maximum particle size of elastomer in μm 2.2 0.25 0.820.31 resin composition Number of elastomers (particle size: 0.5 piece 90 2 0 to 1.0 μm) in resin composition (Physical properties) DTUL (1.82MPa) ° C. 155 132 177 183 MFR (280° C./10 kg) g/10 min 10 213 8.1 3.8Charpy impact strength kJ/m2 14.7 13.2 7.6 13.6 Molding appearance(fogging) poor good good good Presence or absence of flow mark of moldedpiece presence absence absence absence Peeling (ISO dumbbell bending)poor good good good (peeling)

As shown in Table 2, the dispersion form of component (C) was within thescope recited in present invention in Examples 8 to 13. Therefore,Examples 8 to 13 provided resin compositions having high impactresistance and a high peeling preventing effect.

In particular, Examples 9 to 13 provided the resin compositions havingwell-balanced physical properties such as heat resistance, moldingfluidity and impact resistance, and exhibiting good molding appearancehaving no flow mark and no fogging feeling occurring on the surface ofthe molded article. The resin compositions could be suitably used as themolded article for applications to light-reflecting parts and the like.

Meanwhile, in the resin composition of Comparative Example 3, thedispersion particle size of component (C) was small, and the numberaverage particle size was beyond the scope recited in the presentinvention. Therefore, the resin composition was a brittle material anddid not have sufficient impact resistance.

In each of the resin compositions of Comparative Examples 4 and 5, manyof components (C) had a larger dispersion particle size in the resincomposition, and the number average particle size was also beyond thescope recited in the present invention. Therefore, the peelingproperties of the molded article were not sufficient; the molded articlehad defects such as fogging feeling and flow mark; and practicallysufficient appearance properties were not obtained.

Example 14

82% by mass of (PPE1), 10% by mass of (GPPS), 6% by mass of an(elastomer 1), and 2% by mass of an (elastomer 2) were used. A resincomposition was obtained in the same manner as in Example 1 except forthe condition. The measurement results of physical properties of theobtained resin composition are shown in following Table 3.

Example 15

82% by mass of (PPE1), 10% by mass of (GPPS), 6% by mass of an(elastomer 1), and 2% by mass of an (elastomer 2) were used. A screwrotation speed was changed to 550 rpm from 400 rpm, and an extrusionrate was changed to 250 kg/hr from 400 kg/hr. A resin composition wasobtained in the same manner as in Example 1 except for the conditions.The measurement results of physical properties of the obtained resincomposition are shown in following Table 3.

Example 16

72% by mass of (PPE2), 20% by mass of (GPPS), 6% by mass of an(elastomer 1), and 2% by mass of an (elastomer 2) were used.

A screw rotation speed was changed to 550 rpm from 400 rpm, and anextrusion rate was changed to 250 kg/hr from 400 kg/hr. A resincomposition was obtained in the same manner as in Example 1 except forthe conditions. The measurement results of physical properties of theobtained resin composition are shown in following Table 3.

Example 17

82% by mass of (PPE1), 10% by mass of (GPPS), 4% by mass of an(elastomer 1), and 4% by mass of an (elastomer 4) were used. A resincomposition was obtained in the same manner as in Example 1 except forthe condition. The measurement results of physical properties of theobtained resin composition are shown in following Table 3.

Example 18

82% by mass of (PPE1), 10% by mass of (GPPS), 4% by mass of an(elastomer 1), and 4% by mass of an (elastomer 4) were used.

A screw rotation speed was changed to 550 rpm from 400 rpm, and anextrusion rate was changed to 200 kg/hr from 400 kg/hr. A resincomposition was obtained in the same manner as in Example 1 except forthe conditions. The measurement results of physical properties of theobtained resin composition are shown in following Table 3.

Example 19

72% by mass of (PPE2), 20% by mass of (GPPS), 2% by mass of an(elastomer 3), and 6% by mass of an (elastomer 4) were used.

A screw rotation speed was changed to 550 rpm from 400 rpm, and anextrusion rate was changed to 200 kg/hr from 400 kg/hr. A resincomposition was obtained in the same manner as in Example 1 except forthe conditions. The measurement results of physical properties of theobtained resin composition are shown in following Table 3.

TABLE 3 Example 14 Example 15 Example 16 Example 17 Example 18 Example19 (Adding) % by mass PPE1 (component A) η = 0.32 dl/g 82 82 82 82 PPE2(component A) η = 0.42 dl/g 72 72 GPPS (component B) 10 10 20 10 10 20Elastomer 1 (component C) 6 6 6 4 4 Elastomer 2 (component C) 2 2 2Elastomer 3 (component C) 2 Elastomer 4 (component C) 4 4 6 Total 100100 100 100 100 100 (Extrusion condition) Extrusion rate kg/hr 400 250250 400 250 200 Screw rotation speed rpm 400 550 500 400 550 550 Numberaverage particle size of elastomer in resin μm 0.05 0.04 0.04 0.13 0.130.20 composition Maximum particle size of elastomer in resin μm 0.800.52 0.53 0.72 0.26 0.23 composition Number of elastomers (particle sizeof 0.5 to piece 7 2 2 11 0 0 1.0 μm) in resin composition (Physicalproperties) DTUL (1.82 MPa) ° C. 160 160 147 163 161 156 MFR (280° C./10kg) g/10 min 22 24 17 24 26 17 Charpy impact strength kJ/m2 5.8 5.5 3.62.8 2.7 4.1 Molding appearance (fogging) poor good good poor good goodPresence or absence of flow mark of molded piece presence absenceabsence presence absence absence Peeling (ISO dumbbell bending) goodgood good good good good

As shown in Table 3, in Examples 14 to 19, the dispersion form ofcomponent (C) was within the scope recited in the present invention.Therefore, Examples 14 to 19 provided resin compositions having highimpact resistance and a high peeling preventing effect.

In particular, each of the resin compositions of Examples 15, 18, and 19in Table 3 had the same composition as that of each of Example 14 andExample 17 in Table 3 and Comparative Example 4 in Table 2. However,there was obtained resin compositions having well- balanced physicalproperties such as heat resistance, molding fluidity and impactresistance, and exhibiting good appearance properties without havingflow mark and fogging feeling occurring on the surface of the moldedarticle since the extrusion condition was adjusted to improve thedispersibility of component (C), thereby improving the dispersion form.Therefore, the resin compositions could be suitably used as the moldedarticle for applications to light-reflecting parts and the like.

The resin composition of Example 16 had a composition close to that ofthe resin composition of Example 7 in Table 1, and the amount of the(elastomer 2) component was increased as the resin composition.Therefore, in the same extrusion condition as that of Example 7, moredispersion particles of component (C) were predicted to tend to have alarger diameter. However, there were obtained resin compositions havingwell-balanced physical properties such as heat resistance, moldingfluidity and impact resistance, and exhibiting good appearanceproperties without having flow mark and fogging feeling occurring on thesurface of the molded article since the extrusion condition was adjustedto improve the dispersibility of component (C). Therefore, the resincompositions could be suitably used as the molded article forapplications to light-reflecting parts and the like.

The present application is based on Japanese Patent Application(Japanese Patent Application No. 2013-086736) filed to the Japan patentoffice on Apr. 17, 2013, the contents of which are herein incorporatedby reference.

INDUSTRIAL APPLICABILITY

The resin composition of the present invention has industrialapplicability as a molded article for an automotive lamp extension, anda molded article for a light-reflecting part.

1. A molded article for a light-reflecting part comprising a resincomposition comprising: 60 to 93% by mass of polyphenylene ether (A); 35to 0% by mass of styrene-based resin (B); and 15 to 7% by mass ofelastomer component (C), wherein a reduced viscosity of thepolyphenylene ether (A), measured in a 0.5 g/dl solution under atemperature condition of 30° C. using a chloroform solvent, is 0.25 to0.45 dl/g; the styrene-based resin (B) is a non-rubber-reinforcedstyrene-based resin; the elastomer component (C) comprises a blockcopolymer having a styrene block and a hydrogenated conjugated dienecompound block; the elastomer component (C) is present as dispersionparticles in the resin composition; and the dispersion particles have anumber average particle size of 0.04 to 0.25 μm; and the dispersionparticles having a particle size of greater than 1.0 μm are not presentand the number of the dispersion particles having a particle size of 0.5to 1.0 μm is 3 or less in an area corresponding to 396 μm² as measuredby transmission electron microscopy.
 2. The molded article for thelight-reflecting part according to claim 1, wherein the elastomercomponent (C) comprises an oil-extended styrene block-hydrogenatedconjugated diene compound block copolymer.
 3. The molded article for thelight-reflecting part according to claim 2, wherein the elastomercomponent (C) comprises an oil-extended styrene block-hydrogenatedconjugated diene compound block copolymer having an oil-extended amountof 20 to 50% by mass.
 4. The molded article for the light-reflectingpart according to claim 2, wherein the elastomer component (C) comprisesthe oil-extended styrene block-hydrogenated conjugated diene compoundblock copolymer having an oil-extended amount of 20 to 50% by mass andan olefin-based elastomer in a mass ratio of (the oil-extended styreneblock-hydrogenated conjugated diene compound block copolymer having anoil-extended amount of 20 to 50% by mass: the olefin-basedelastomer)=9:1 to 3:7.
 5. The molded article for the light-reflectingpart according to claim 2, wherein the resin composition comprises 15 to100 parts by mass of an oil based on 100 parts by mass of the styreneblock-hydrogenated conjugated diene compound block copolymer.
 6. Theresin composition according to claim 1, wherein the component (C)comprises a styrene block-hydrogenated conjugated diene compound blockcopolymer and/or an oil-extended styrene block-hydrogenated conjugateddiene compound block copolymer and an olefin-based elastomer in a massratio of (the styrene block-hydrogenated conjugated diene compound blockcopolymer and/or the oil-extended styrene block-hydrogenated conjugateddiene compound block copolymer/the olefin-based elastomer)=9:1 to 3:7,and the resin composition comprises 15 to 100 parts by mass of an oilbased on 100 parts by mass of the styrene block-hydrogenated conjugateddiene compound block copolymer.
 7. A molded article for an automotivelamp extension comprising a resin composition comprising: 60 to 93% bymass of polyphenylene ether (A); 35 to 0% by mass of styrene-based resin(B); and 15 to 7% by mass of elastomer component (C), wherein a reducedviscosity of the polyphenylene ether (A), measured in a 0.5 g/dlsolution under a temperature condition of 30° C. using a chloroformsolvent, is 0.25 to 0.45 dl/g; the styrene-based resin (B) is anon-rubber- reinforced styrene-based resin; the elastomer component (C)comprises a block copolymer having a styrene block and a hydrogenatedconjugated diene compound block; the elastomer component (C) is presentas dispersion particles in the resin composition; and the dispersionparticles have a number average particle size of 0.04 to 0.25 μm; andthe dispersion particles having a particle size of greater than 1.0 μmare not present and the number of the dispersion particles having aparticle size of 0.5 to 1.0 μm is 3 or less in an area corresponding to396 μm² as measured by transmission electron microscopy.
 8. The moldedarticle for the light-reflecting part according to claim 2, wherein thecomponent (C) comprises a styrene block-hydrogenated conjugated dienecompound block copolymer and/or an oil-extended styreneblock-hydrogenated conjugated diene compound block copolymer and anolefin-based elastomer in a mass ratio of (the styreneblock-hydrogenated conjugated diene compound block copolymer and/or theoil-extended styrene block-hydrogenated conjugated diene compound blockcopolymer/the olefin-based elastomer)=9:1 to 3:7, and the resincomposition comprises 15 to 100 parts by mass of an oil based on 100parts by mass of the styrene block-hydrogenated conjugated dienecompound block copolymer.
 9. The molded article for the automotive lampextension according to claim 8, wherein the elastomer component (C)comprises an oil-extended styrene block-hydrogenated conjugated dienecompound block copolymer.